Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
  • C08J5/18—Manufacture of films or sheets
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2367/00—Characterised by the use of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Derivatives of such polymers
  • C08J2367/04—Polyesters derived from hydroxy carboxylic acids, e.g. lactones
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10S428/00—Stock material or miscellaneous articles
  • Y10S428/913—Material designed to be responsive to temperature, light, moisture

Definitions

• a conventional disposable absorbent product is already to a large extent compostable.
• a typical disposable diaper for example, consists of about 80% of compostable materials, e.g., wood pulp fibers, and the like.
• compostable materials e.g., wood pulp fibers, and the like.
• soiled disposable absorbent articles are shredded and commingled with organic waste prior to the composting per se. After composting is complete, the non-compostable particles are screened out. In this manner even today's absorbent articles can successfully be processed in commercial composting plants.
• the films employed as backsheets for absorbent articles must satisfy many other performance requirements.
• the resins should be thermoplastic such that conventional film processing methods can be employed. These methods include cast film and blown film extrusion of single layer structures and cast or blown film coextrusion of multilayer structures. Other methods include extrusion coating of one material on one or both sides of a compostable substrate such as another film, a non-woven fabric, or a paper web.
• the absorbent article Once the absorbent article is disposed of and enters a composting process, other properties become important. Regardless of whether incoming waste is preshredded or not, it is important that the film or large film fragments undergo an initial breakup to much smaller particles during the initial stages of composting. Otherwise, the films or large fragments may be screened out of the compost stream and may never become part of the final compost.
• PHB is thermoplastic having a high degree of crystallinity and a well-defined melt temperature of about 180°C.
• PHB becomes unstable and degrades at elevated temperatures near its melt temperature. Due to this thermal instability, commercial applications of PHB have been extremely limited.
• a film made from PHBV will stick to itself even after cooling; a substantial fraction of the PHBV remains amorphous and tacky for long periods of time.
• molten PHBV often sticks to the rolls restricting the speed at which the film can be processed, or even preventing the film from being collected.
• residual tack of the PHBV causes the tubular film to stick to itself after it has been cooled and collapsed for winding.
• alkyl means a saturated carbon-containing chain which may be straight or branched; and substituted (mono- or poly-) or unsubstituted.
• PHBV means the copolymer poly(3-hydroxybutyrate-co- 3-hydroxyvalerate).
• the present invention relates to biodegradable copolymers which are surprisingly easy to process into plastic articles, particularly into films as compared to the homopolymer PHB and copolymer PHBV.
• plastic article means a copolymer processed into a film, sheet, fiber, foam, molded article, nonwoven fabric, elastomer or adhesive.
• PHAs useful for processing into plastic articles of the present invention comprise at least two randomly repeating monomer units (RRMU).
• the first RRMU has the structure
• R 1 is a C2 alkyl and n is 1 , thereby forming the monomeric repeat unit 3-hydroxyvalerate.
• R1 is H and n is 1 , thereby forming the monomeric repeat unit 3-hydroxypropionate.
• R ⁇ is a C-
• R is a C-
• R ⁇ is a C2 alkyl and m is 1 , thereby forming the monomeric repeat unit 3-hydroxyvalerate.
• R ⁇ is H and m is 2, thereby forming the monomeric repeat unit 4-hydroxybutyrate.
• R ⁇ is H and m is 1 , thereby forming the monomeric repeat unit 3-hydroxypropionate.
• RRMUs wherein at least 50% of the RRMUs have the structure of the first RRMU.
• novel biodegradable PHAs of the present invention comprising three RRMUs, have a first RRMU having the structure
• R1 is H, or C-
• R is H, or a C-
• the production of isotactic polymer can be accomplished by polymerization of an enantiomerically pure monomer and a non-racemizing initiator, with either retention or inversion of configuration of the stereocenter, or by polymerization of racemic monomer with an initiator which preferentially polymerizes one enantiomer.
• a non-racemizing initiator for example:
• the naturally derived PHAs of the present invention are isotactic and have the R absolute configuration at the stereocenters in the polymer backbone.
• isotactic polymers may be made where the configuration of the stereocenters is predominantly S. Both isotactic materials will have the same physical properties and most of the same chemical reactivities except when a stereospecific reagent, such as an enzyme, is involved.
• Atactic polymers polymers with random incorporation of R and S stereocenters, can be produced from racemic monomers and polymerization initiators or catalysts that show no preference for either enantiomer while such initiators or catalysts often polymerize monomers of high optical purity to isotactic polymer (e.g., distannoxane catalysts) (see Hori, Y., M. Suzuki, Y. Takahashi, A. Yamaguchi, T. Nishishita, MACROMOLECULES, Vol. 26, pp. 5533-5534 (1993)).
• isotactic polymer can be produced from racemic monomers if the polymerization catalyst has an enhanced reactivity for one enantiomer over the other.
• stereo-block copolymers or a mixture of stereo-block copolymers and stereo- homopolymers may be produced (see Le Borgne, A. and N. Spassky, N., POLYMER, Vol. 30, pp. 2312-2319 (1989); Tanahashi, N., and Y. Doi, MACROMOLECULES, Vol. 24, pp. 5732-5733 (1991 ); and Benvenuti, M. and R.W. Lenz, J. POLYM. SCI.: PART A: POLYM. CHEM., Vol. 29, pp. 793-805 (1991 )).
• Some initiators or catalysts are known to produce predominantly syndiotactic polymers, polymers with alternating R and S stereocenter repeat units, from racemic monomers (see Kemnitzer, J. E., S.P. McCarthy and R.A. Gross, MACROMOLECULES, Vol. 26, pp. 1221-1229 (1993)) while some initiators or catalysts may produce all three types of stereopolymers (see Hocking, P. J. and R.H. Marchessault, POLYM. BULL., Vol. 30, pp. 163-170 (1993)).
• the polymerization catalyst is added as a toluene solution via syringe.
• the tube is carefully swirled to mix the reagents (but not contact the rubber septum) and then heated in an oil bath at the desired temperature for the prescribed time.
• the mixture becomes viscous and may solidify. If isotactic polymer is produced, solid polymer precipitates out until the entire mass solidifies.
• the product can then be cooled, removed from the tube, and rid of residual monomer by vacuum drying.
• the product can be dissolved in an appropriate solvent (e.g., chloroform) and recovered by precipitation in a nonsolvent (e.g., ether-hexane mixture, 3:1 v/v), and vacuum dried.
• Molecular weight is determined by standard methods such as size exclusion chromatography (SEC, also known as gel permeation chromatography or GPC).
• the comonomer content of the polymers is determined by nuclear magnetic resonance (NMR).
• the initiator is an alkylzinc alkoxide, as disclosed in the US Patent No. 5,648,452 entitled "Polymerization of Beta-Substituted-Beta-Propiolactones Initiated by Alkylzinc Alkoxides", L.A. Schechtman and J.J. Kemper, assigned to The Procter and Gamble Company, issued July 13, 1997.
• Such initiators have the general formula R 1 ZnOR2, wherein R 1 and R ⁇ are independently a C-
• the initiator is selected from the group consisting of ethylzinc isopropoxide, methylzinc isopropoxide, ethylzinc ethoxide, or ethylzinc methoxide; more preferably ethylzinc isopropoxide.
• copolymers useful in the present invention can be made by substituting the starting materials (monomers) in the above procedure with 3- alkyl- ⁇ -lactones corresponding to the monomer units desired in the final copolymer product.
• biodegradable PHAs useful in the present invention may be carried out by fermentation with the proper organism (natural or genetically engineered) with the proper feedstock (single or multicomponent). Biological synthesis may also be carried out with botanical species genetically engineered to express the copolymers of interest (see World Patent Application No. 93-02187, Somerville, Poirier and Dennis, published February 4, 1993; and U.S. Patent No. 5,650,555, Dennis et al., issued July 22, 1997, and U.S. Patent No. 5,610,041 , Nawrath et al., issued March 11 , 1997; and Poole, R., SCIENCE, Vol. 245, pp. 1187-1189 (1989)).
• the volume percent crystallinity ( ⁇ c ) of a semi-crystalline polymer (or copolymer) often determines what type of end-use properties the polymer possesses. For example, highly (greater than 50%) crystalline polyethylene polymers are strong and stiff, and suitable for products such as plastic milk containers. Low crystalline polyethylene, on the other hand, is flexible and tough, and is suitable for products such as food wraps and garbage bags. Crystallinity can be determined in a number of ways, including x-ray diffraction, differential scanning calorimetry (DSC), density measurements, and infrared absorption. The most suitable method depends upon the material being tested.
• DSC differential scanning calorimetry
• X-ray diffraction is most appropriate when little is known about the thermal properties of the material and crystal structural changes may occur.
• the basic principle relies on the fact that amorphous parts of the material scatter x- rays in a diffuse or broad range of angles, while crystals diffract x-rays into sharp, precisely defined angles.
• the total scattered intensity is constant, however. This allows calculation of the amount of crystalline material in a sample if the amorphous and crystalline diffracted intensities can be separated.
• a very precise method has been developed by Ruland, which can detect differences in percent crystallinity as small as 2% (see Vonk, C, F.J.
• PHAs of the present invention preferably have a crystallinity of from about 0.1 % to about 99% as measured via x-ray diffraction; more preferably from about 2% to about 80%; more preferably still from about 20% to about 70%.
• the amount of crystallinity in such PHA is more preferably from about 2% to about 65% as measured via x-ray diffraction; more preferably from about 5% to about 50%; more preferably still from about 20% to about 40%.
• the amount of crystallinity in such PHA is more preferably from about 0.1% to about 50% as measured via x-ray diffraction; more preferably from about 5% to about 50%; more preferably still from about 20% to about 40%.
• the amount of crystallinity in such PHA is more preferably from about 60% to about 99% as measured via x-ray diffraction; more preferably from about 70% to about 99%; more preferably still from about 80% to about 99%.
• the amount of crystallinity in such PHA is more preferably from about 30% to about 80% as measured via x-ray diffraction; more preferably from about 40% to about 80%; more preferably still from about 50% to about 80%.
• the amount of crystallinity in such PHA is more preferably from about 10% to about 80% as measured via x-ray diffraction; more preferably from about 20% to about 70%; more preferably still from about 30% to about 60%.
• the amount of crystallinity in such PHA is more preferably less than about 50% as measured via x-ray diffraction; more preferably less than about 30%; more preferably still less than about 20%.
• the biodegradable PHAs of the present invention have a melt temperature (Tm) of from about 30°C to about 160°C, more preferably from about 60°C to about 140°C, more preferably still from about 90°C to about 120° C.
• Tm melt temperature
• the PHAs of the present invention can be processed into a variety of plastic articles, including but not limited to, films, sheets, fibers, foams, molded articles, nonwoven fabrics, elastomers, and adhesives.
• plastic articles including but not limited to, films, sheets, fibers, foams, molded articles, nonwoven fabrics, elastomers, and adhesives.
• the plastic article is a film.
• film means an extremely thin continuous piece of a substance having a high length to thickness ratio and a high width to thickness ratio. While there is no requirement for a precise upper limit of thickness, a preferred upper limit would be 0.254 mm, more preferably still about 0.01 mm, more preferably still about 0.005 mm.
• the protective value of any film depends on its being continuous, i.e., without holes or cracks, since it must be an efficient barrier to molecules such as atmospheric water vapor and oxygen.
• the film of the present invention can be employed in a variety of disposable products including, but not limited to, disposable diapers, shrink-wrapping (e.g., food wraps, consumer product wraps, pallet and/or crate wraps, and the like), or bags (grocery bags, food storage bags, sandwich bags, resealable "Ziploc®"-type bags, garbage bags, and the like).
• the film of the present invention is liquid impervious and suitable for use in absorbent disposable sanitary garments such as disposable diapers, feminine hygiene products and the like.
• films of the present invention in addition to increased biodegradability and/or compostability, have the following properties: a) a machine direction (MD) tensile modulus from about 10,000 to about 100,000 ibs./sq. in. (6.895 x 10 8 dynes/sq. cm to 6.895 x 10 9 dynes/sq.
• MD machine direction
• a MD tear strength of at least 70 grams per 25.4 ⁇ m of thickness b) a MD tear strength of at least 70 grams per 25.4 ⁇ m of thickness, c) a cross machine direction (CD) tear strength of at least 70 grams per 25.4 ⁇ of thickness, d) an impact strength of at least 12 cm as measured by falling ball drop, e) a moisture transport rate less than about 0.0012 grams per square centimeter per 16 hours, f) a modulus at 60°C of at least 5.52 x 10 7 dynes/sq. cm (800 Ibs./sq. in), and g) a thickness from about 12 ⁇ m to about 75 ⁇ m. Methods for testing for such performance criteria are discussed in more detail below.
• polyhydroxyalkanoates studied for use in commercial plastics production presented significant impediments to their use in plastics.
• polyhydroxyalkanoates such as PHB and the copolymer PHBV are difficult to process due to their thermal instability.
• polyhydroxyalkanoates were especially difficult to process into films due to their slow crystallization rate.
• PHA copolymers of the present invention which comprise a second RRMU as defined above having a branched alkyl of three (3) carbons, are surprisingly easier to process into films, especially as compared to PHB or PHBV.
• characteristics a) and b) are achieved by exclusion of the second RRMU from the crystal lattice of the first RRMU, thereby resulting in a decreased temperature for thermal processing and improved stiffness and elongation properties.
• characteristic c) is achieved by increased entanglement between the copolymer chains due to the side chains of the second RRMU.
• Such increased entanglement may occur by increased hydrodynamic volume of the copolymer (e.g., the second monomer unit creates kinks in the helical structure), the "hooking" or “catching” of the side chains on different copolymer backbones while in the melt, or the decreased chain scission due to the lower Tm (i.e., the enlarged thermal process window).
• the backsheets of disposable diapers must have sufficient strength both to process on a high speed disposable diaper converting machine and to provide a "wetproof" barrier in use on an infant. It must be sufficiently wetproof so that the clothing or bedding, either that of the infant or of the caregiver, is not wet or soiled. It must have a modulus or flexibility that is, at the same time, low enough to be a soft, pleasing material to be used as the outer covering of an infant diaper yet high enough to handle easily on high speed disposable diaper converters without wrinkling, folding, or creasing. It must have sufficient resistance to heat such that it will not deform, melt, or permanently loose strength in typical hot storage conditions or loose its integrity on high speed disposable diaper converters which typically use hot melt adhesives to bond the components of a disposable diaper together.
• Films that are sufficiently strong to be suitable as biodegradable and/or compostable backsheets for disposable diapers preferably demonstrate two properties: (a) resistance to rupture from a dropped weight and (b) resistance to tearing in both the machine direction of manufacture and the cross-machine direction of manufacture.
• Preferred backsheets of the present invention can withstand the drop of a spherical steel ball of about 19 millimeters in diameter and 27.6 to 28.6 gram mass from a height of 12 centimeters so that at least 50% of the tests result in no rupture of any size (deformation is acceptable).
• Preferred materials are those that exhibit 50% or less failures from a height of more than 20 centimeters.
• acceptable backsheets of the present invention demonstrate an average tear propagation resistance of 70 grams per 25.4 micron thickness of material in both the machine direction and cross- machine direction of manufacture when a standard Elmendorf pendulum-type test device, such as Elmendorf Model No. 60-100, is employed against 16 plies of material which have been prepared with a cut or notch according to TAPPI Method T 414om-88. More preferable are those backsheets that demonstrate tear propagation resistances of 200 or more grams per 25.4 micron thickness in the cross-machine direction because these are particularly good at avoiding a tendency to fail in use by splitting.
• Vicat softening is tested using a Heat Distortion Apparatus Model No. CS-107 or equivalent and a modification of ASTM D-1525. The modification is in the preparation of the sample.
• a 19 square millimeter size film of 4.5 to 6.5 mm thickness is prepared for Vicat needle penetration tests by melting the material to be tested into a mold using a temperature of 120°C and pressure of 7.031 x 10 ⁇ g/cm 2 (10,000 psi) (using a Carver or similar press) for two minutes after a warm-up period of at least 2 minutes.
• the Vicat softening point is the temperature at which a flat- ended needle of 1 sq. mm circular cross section will penetrate the sample to a depth of 0.1 cm under a load 1000 g using a uniform temperature rise rate of 50°C per hour.
• the test strip is clamped into the jaws of the tensile testor so that the gauge or actual length of the material tested is 25.4 cm
• the jaws are separated at a slow speed in the range of 2.54 cm per minute to 25.4 cm per minute and a stress-strain curve is plotted on a chart within an attached recording device.
• the 1% secant modulus is determined by reading the stress or tensile from the chart at the 1 % elongation strain point. For example, the 1 % strain point is achieved when the distance between jaws has increased by 0.254 cm.
• absorbent articles may experience temperatures as high as 140°F (60°C) during warehouse storage or shipping in trucks or railcars, it is important that the backsheet film and other components retain their integrity at these temperatures. Although it is expected that the modulus of the films will decrease somewhat between 20°C and 60°C, the modulus should not decrease too far and allow the film to deform in the package before it reaches the end user.
• a polyethylene backsheet with a room temperature modulus of about 4 x 10 9 dynes/cm 2 (58,000 psi) may have a 60°C modulus of 1.2 x 10 9 dynes/cm 2 (18,560 psi) which is acceptable.
• a softer polyethylene backsheet with a room temperature modulus of about 8.0 x 10 8 dynes/cm 2 (11 ,600 psi) may have a 60°C modulus of about 3.5 x 10 8 dynes/cm 2 (5,076 psi) which is still acceptable.
• an acceptable backsheet film of the present invention will have a 60°C modulus of at least 5.52 x 10 7 dynes/cm 2 (800 psi).
• the modulus dependence on temperature also called a modulus/temperature spectrum
• a dynamic mechanical analyzer such as a Perkin Elmer 7 Series/Unix TMA 7 Thermomechanical Analyzer equipped with a 7 Series/Unix DMA 7 Temperature/Time software package, hereinafter referred to as the DMA 7, available from the Perkin-Elmer Corporation of Norwalk, Connecticut.
• DMA dynamic mechanical analyzer
• the DMA 7 is set to run in temperature scan mode and equipped with an extension measuring system (EMS).
• EMS extension measuring system
• a film specimen approximately 3 mm wide, 0.0254 mm thick, and of sufficient length to allow 6 to 8 mm of length between the specimen grips is mounted in the EMS.
• the apparatus is then enclosed in an environmental chamber swept continuously with helium gas. Stress is applied to the film in the length direction to achieve a deformation or strain of 0.1 percent of the original length.
• a dynamic sinusoidal strain is applied to the specimen at a frequency of 5 cycles per second.
• the temperature scan mode the temperature is increased at a rate of 3.0°C/minute from 25°C to the point where the specimen melts or breaks, while the frequency and stress are held constant.
• Temperature-dependent behavior is characterized by monitoring changes in strain and the phase difference in time between stress and strain.
• Storage modulus values in Pascals are calculated by the computer along with other data and displayed as functions of temperature on a video display terminal. Normally the data are saved on computer disk and a hard copy of the storage modulus/temperature spectrum printed for further review. The 60°C modulus is determined directly from the spectrum.
• the films of the present invention used as backsheets having increased biodegradability and/or compostability may be processed using conventional procedures for producing single or multilayer films on conventional film-making equipment.
• Pellets of the PHAs of the present invention can be first dry blended and then melt mixed in a film extruder. Alternatively, if insufficient mixing occurs in the film extruder, the pellets can be first dry blended and then melt mixed in a precompounding extruder followed by repelletization prior to film extrusion.
• the PHAs of the present invention can be melt processed into films using either cast or blown film extrusion methods both of which are described in PLASTICS EXTRUSION TECHNOLOGY--2nd Ed., by Allan A. Griff (Van Nostrand Reinhold-1976).
• Cast film is extruded through a linear slot die.
• the flat web is cooled on a large moving polished metal roll. It quickly cools, and peels off this first roll, passes over one or more auxiliary cooling rolls, then through a set of rubber-coated pull or "haul-off' rolls, and finally to a winder.
• a method of making a cast backsheet film for the absorbent articles of the present invention is described in an example below.
• the melt is extruded upward through a thin annular die opening.
• This process is also referred to as tubular film extrusion.
• Air is introduced through the center of the die to inflate the tube and thereby causing it to expand.
• a moving bubble is thus formed which is held at a constant size by control of internal air pressure.
• the tube of film is cooled by air, blown through one or more chill rings surrounding the tube.
• the tube is then collapsed by drawing it into a flattening frame through a pair of pull rolls and into a winder.
• the flattened tubular film is subsequently slit open, unfolded, and further slit into widths appropriate for use in products.
• Both cast film and blown film processes can be used to produce either monolayer or multilayer film structures.
• monolayer films from a single thermoplastic material or blend of thermoplastic components only a single extruder and single manifold die are required.
• coextrusion processes are preferably employed. Such processes require more than one extruder and either a coextrusion feedblock or multi-manifold die system or combination of the two to achieve the multilayer film structure.
• Each manifold in a vane die can be designed and tailored to a specific polymer (or copolymer). Thus the flow of each polymer is influenced only by the design of its manifold, and not by forces imposed by other polymers. This allows materials with greatly differing melt viscosities to be coextruded into multilayer films.
• the vane die also provides the ability to tailor the width of individual manifolds, such that an internal layer, for example a water soluble biodegradable polymer like Vinex 2034, can be completely surrounded by water insoluble materials leaving no exposed edges susceptible to water.
• the aforementioned patents also disclose the combined use of feedblock systems and vane dies to achieve more complex multilayer structures.
• the multilayer films of the present invention may comprise two or more layers.
• balanced or symmetrical three-layer and five-layer films are preferred.
• Balanced three-layer multilayer films comprise a center core layer and two identical outer layers, wherein said center core layer is positioned between said two outer layers.
• Balanced five-layer multilayer films comprise a center core layer, two identical tie layers, and two identical outer layers, wherein said center core layer is positioned between said two tie layers, and a tie layer is positioned between said center core layer and each outer layer.
• Balanced films, though not essential to the films of the present invention, are less prone to curling or warping than unbalanced multilayer films.
• the plastic article is a sheet.
• sheet means a very thin continuous piece of a substance, having a high length to thickness ratio and a high width to thickness ratio, wherein the material is thicker than 0.254 mm. Sheeting shares many of the same characteristics as film in terms of properties and manufacture, with the exception that sheeting is stiffer, and has a self-supporting nature. Such differences in stiffness and support result in some modification of the manufacturing methods. 1. Methods of Manufacture
• calendering To produce an unoriented cast film or sheet with high throughput, calendering is used (G. W. Eghmy, Jr. in MODERN PLASTICS, J. Agrandoff, ed. Encyclopedia, Vol 59(10A), pp. 220-222 (1982) and R. A. Elden and A. D. Swan, CALENDERING OF PLASTICS, American Elsevier Co., Inc., New York, (1971)).
• the calendering process employs stacks of specially hardened, driven rolls, supported in a manner so they may be bent or skewed in position relative to each other during operation. This is to control thickness in the calendered material. Calenders are usually made up of four rolls that form three nips.
• nips are the feed, metering and finishing nips.
• the feed nip is where the polymer is supplied, mixed, and heated.
• the metering nip reduces the thickness of the sheet to the approximate final thickness.
• the finishing nip adjusts the gauge of the sheet by varying the position of the third or middle roll, (see EPSE-
• a PHA of the present invention is heated above its melting point and the molten PHA is forced through a spinneret.
• a spinneret is a die with many small orifices which are varied in number, shape and diameter (see EPSE-2).
• the jet of molten PHA is passed through a cooling zone where the PHA solidifies and is then transferred to post-drawing and take-up equipment.
• the plastic article is a flexible foam.
• foam refers PHA of the present invention whose apparent density has been substantially decreased by the presence of numerous cells distributed throughout its bulk (see ASTM D 883-62T, American Society for Testing and Materials, Philadelphia, Pa., (1962)).
• Such two-phase gas/solid systems in which the solid is continuous and composed of a synthetic polymer or rubber include cellular polymers (or copolymers), expanded plastics and foamed plastics (ENCYCLOPEDIA OF CHEMICAL TECHNOLOGY, Vol. 11 , John Wiley & Sons, New York (1980), hereinafter referred to as "ECT").
• Foams are further categorized into flexible and rigid foams. This classification is based on a particular ASTM test procedure (see ASTM D, Vol. 37, pp. 1566-1578, American Society of Testing and Materials, Philadelphia, Pa., (1978)).
• a flexible foam is a foam which does not rupture when a 20 x 2.5 x 2.5 cm piece is wrapped around a 2.5 cm mandrel at a uniform rate of 1 lap/5s at 15-25°C. Foams that do rupture under this test are referred to as rigid foams.
• the foams of the present invention may be processed using conventional procedures well-known to those skilled in the art.
• a predominant method of foam production involves expanding a fluid polymer (or copolymer) phase to a low density cellular phase and then preserving this state (see ECT).
• Other processes include leaching out materials that have been previously dispersed in the polymer (or copolymer), sintering small particles and dispersing cellular particles in a polymer (or copolymer).
• Three steps make up the expansion process. These are cell initiation, cell growth and cell stabilization. Many methods are used to create, grow, and stabilize cells.
• the nonwoven fabrics of the present invention may be made by conventional techniques known in the art.
• the production of nonwoven fabrics involves: 1 ) making fibers of various lengths and diameters; 2) creating a web of these fibers; and 3) bonding of fibers within the web by adhesive, or mechanical-frictional forces created by fiber contact or entanglement.
• reinforcing the web by forming a composite with other materials e.g., yarns, scrims, films, nettings, and unbonded webs
• Variations of one or several of these steps allows for the enormous range of nonwoven fiber types.
• Important fiber characteristics that affect performance include length, diameter, density, crimp, cross section shape, spin-finish (lubricant that is added to the surface of extruded fibers to enhance processability), delustering (small amounts of Ti ⁇ 2 pigment added before extrusion to increase whiteness or to reduce sheen) and the draw ratio, a. Web-making methods
• the choice of method for forming the web is determined by fiber length.
• the methods for forming webs from staple-length fibers are based on the textile-carding process, whereas web formation from short fibers is based on papermaking technologies. Although these technologies are still in use, other methods have been subsequently developed. For example, webs are formed from long, virtually endless filaments directly from bulk polymer; both web and fibers are produced simultaneously (see EPSE-4).
• a variety of web-making methods are known, including carding, air-laying, wet-forming, spinbonding, and meltblowing.
• the carding process is derived from the ancient manual methods of fiber carding, where natural staple fibers were manipulated by beds of needles. In carding, clumps of staple fibers are separated mechanically into individual fibers and formed into a coherent web by the mechanical action of moving beds of closely spaced needles.
• the spunbonded web process involves making fibers and web simultaneously, directly from bulk polymer.
• the bulk polymer is melted, extruded, and drawn (often by triboelectric forces) to filaments that are randomized and deposited onto belts as a continuous web.
• the filaments are virtually endless.
• the spunbond process produces webs of low crimp filaments in the normal diameter range of about 1.7 dtex (1.5 den) or slightly higher.
• the birefringence and uniformity of diameter of these filaments are similar to standard textile fibers and filaments (see EPSE-4).
• Each production line is suitable for a specific polymer and a single-bonding system (see U.S. Pat. 4,163,305 (Aug. 7, 1979), V. Semjonow and J. Foedrowitz (to Hoechst AG)).
• the plastic article is an elastomer.
• elastomer refers to materials which exhibit both long-range deformability on application of stress and essentially complete recovery on removal.
• a general discussion on elastomers can be found in the Encyclopedia of Polymer Science and Engineering, Second Edition, Vol. 5, pp. 106-127 (hereafter referred to as "EPSE-5").
• an elastomer of the present invention at room temperature, can be stretched repeatedly to at least twice its original length and, after removal of the tensile load, will immediately and forcibly return to approximately its original length.
• Elastomers of the present invention are above the glass-transition temperature Tg and amorphous in the unstressed state to exhibit high local segmental mobility necessary for deformation.
• the chains are flexible and intermolecular (interchain) forces are weak.
• the elastomers of the present invention possess a sufficient number of chemical or physical cross-links to form a continuous network in order to restrain chain slippage.
• Thermoplastic elastomers of the present invention have many of the properties of conventional elastomers such as vulcanized rubbers, but are processed as thermoplastics rather than thermosets. Transition from a fluid melt to a solid is reversible.
• Thermoplastic elastomers of the present invention are multiphase systems, where at least one phase is soft and rubbery and another hard. With thermoplastic elastomers, the transition from a processible melt to a solid, rubberlike object is rapid and reversible and takes place upon cooling.
• thermoplastic elastomers Important structural parameters for thermoplastic elastomers are the molecular weight, the nature of the soft and hard segments, and the ratio of soft to hard segments. The ratio of hard to soft segments effects the total modulus of the elastomer, increasing with the proportion of the hard segments.
• the liquid form of the adhesive is obtained by heating to the point that flow occurs, dissolving or dispersing the material in a solvent, or starting with liquid monomers or oligomers that polymerize or react after application.
• the adhesive then undergoes a phase change to a solid either by cooling, solvent evaporation, or reaction, in order for the joint to acquire the necessary strength to resist shearing forces.
• pressure-sensitive adhesives are an exception, since no phase change occurs.
• hot-melt adhesive refers to a thermoplastic polymer or copolymer (e.g., a PHA of the present invention) that is heated to obtain a liquid of flowable viscosity, and, after application, cooled to obtain a solid.
• the molecular weight of the adhesive is tailored to provide flowability in the melt, but still be strong enough in the solid form to resist shearing forces experienced in the application. Due to their thermoplastic properties, the PHAs of the present invention are particularly useful as hot-melt adhesives.
• the primary feature of hot-melt adhesives is the ability of the thermoplastic material to flow above a certain temperature, high above the normal use temperature of the bond. Upon cooling, the material hardens, either through passing through the glass transition temperature of one of the components, or the crystallization temperature. This hardening lends physical integrity to the bond.
• the mode of solidification is crystallization.
• the adhesives of the present invention may be applied either as solutions, in water or an organic solvent, or in the form of aqueous dispersions.
• the solvent must be removed after application for the adhesive to attain the required solid form.
• the solution or dispersion is usually applied to one of the surfaces to be bonded, and the solvent removed before the second surface is joined; often, heating is required to expedite the drying step. With porous substrates, such as paper or wood, final drying can take place after formation of the joint. Solids contents of the solutions vary from 5 to 95%, although values from 20 to 50% are most common.
• dispersions refers to when adhesives are prepared by true emulsion polymerization or dispersed as larger particles in some carrier fluid.
• dispersions containing 40-50% solids offer lower viscosity than solutions, even if the solids are high molecular- weight polymers (EPSE-6).
• Adhesive dispersions of the present invention may be prepared by high shear in the presence of surfactants to obtain waterborne formulations, procedures which are well known to those skilled in the art. 3. Pressure-sensitive Adhesives.
• pressure-sensitive adhesive Another type of adhesive of the present invention is a pressure-sensitive adhesive. Unlike other adhesives, the pressure-sensitive adhesives do not change their physical state from the initial application, to the final breaking of the adhesive bond. They remain permanently deformable, and may alter under even slight application of pressure. They are adhesives that in dry form are permanently tacky at room temperature and that firmly adhere to surfaces upon mere contact. The most common form of pressure-sensitive adhesive is on a backing, usually in tape form. Common masking tape, for example, is manually applied after the user removes the desired length from a roll. Many bandages are held to the skin by pressure-sensitive adhesives.
• the present invention further relates to disposable personal care products comprising a PHA of the present invention.
• disposable personal care products comprising a PHA of the present invention.
• compostable absorbent articles comprising a liquid pervious topsheet, a liquid impervious backsheet comprising a film of the present invention (i.e., a film comprising a PHA of the present invention), and an absorbent core positioned between the topsheet and backsheet.
• absorbent articles include infant diapers, adult incontinent briefs and pads, and feminine hygiene pads and liners.
• Additional personal care products comprising a PHA of the present invention include personal cleansing wipes; disposable health care products such as bandages, wound dressings, wound cleansing pads, surgical gowns, surgical covers, surgical pads; other institutional and health care disposables such as gowns, wipes, pads, bedding items such as sheets and pillowcases, foam mattress pads.
• disposable health care products such as bandages, wound dressings, wound cleansing pads, surgical gowns, surgical covers, surgical pads
• other institutional and health care disposables such as gowns, wipes, pads, bedding items such as sheets and pillowcases, foam mattress pads.
• the liquid impervious backsheet is combined with a liquid pervious topsheet and an absorbent core positioned between the topsheet and the backsheet.
• elastic members and tape tab fasteners can be included. While the topsheet, the backsheet, the absorbent core and elastic members may be assembled in a variety of well known configurations, a preferred diaper configuration is described generally in U.S. Patent 3,860,003, entitled "Contractible Side Portion for Disposable Diaper" which issued to Kenneth B. Buell on January 14, 1975.
• the topsheet is preferably, soft-feeling, and non-irritating to the wearer's skin. Further, the topsheet is liquid pervious, permitting liquids to readily penetrate through its thickness.
• a suitable topsheet may be manufactured from a wide range of materials such as porous foams, reticulated foams, apertured plastic films, natural fibers (e.g., wood or cotton fibers), synthetic fibers (e.g., polyester or polypropylene fibers) or from a combination of natural and synthetic fibers.
• the topsheet is made of a hydrophobic material to isolate the wearer's skin from liquids in the absorbent core.
• a particularly preferred topsheet comprises staple-length fibers having a denier of about 1.5.
• staple-length fibers refers to those fibers having a length of at least about 16 mm.
• the topsheet may be woven, non- woven, spunbonded, carded, or the like.
• a preferred topsheet is carded, and thermally bonded by means well known to those skilled in the fabrics art.
• the topsheet has a weight from about 18 to about 25 g/m 2 , a minimum dried tensile strength of at least about 400 g/cm in the machine direction, and a wet tensile strength of at least about 55 g/cm in the cross- machine direction.
• the top sheet comprises a PHA of the present invention.
• topsheet and the backsheet are joined together in any suitable manner.
• the term "joined” encompasses configurations whereby the topsheet is directly joined to the backsheet by affixing the topsheet directly to the backsheet, and configurations whereby the topsheet is indirectly joined to the backsheet by affixing the topsheet to intermediate members which in turn are affixed to the backsheet.
• the topsheet and the backsheet are affixed directly to each other in the diaper periphery by attachment means such as an adhesive or any other attachment means known in the art.
• attachment means such as an adhesive or any other attachment means known in the art.
• a uniform, continuous layer of adhesive, a patterned layer of adhesive, or an array of separate lines or spots of adhesive may be used to affix the topsheet to the backsheet.
• the adhesive comprises a PHA of the present invention.
• Tape tab fasteners are typically applied to the back waistband region of the diaper to provide a fastening means for holding the diaper on the wearer.
• the tape tab fasteners can be any of those well known in the art, such as the fastening tape disclosed in U.S. Patent 3,848,594 issued to Kenneth B. Buell on November 19, 1974. These tape tab fasteners or other diaper fastening means are typically applied near the corners of the diaper.
• Preferred diapers have elastic members disposed adjacent the periphery of the diaper, preferably along each longitudinal edge so that the elastic members tend to draw and hold the diaper against the legs of the wearer.
• the elastic members are secured to the diaper in an contractible condition so that in a normally unrestrained configuration the elastic members effectively contract or gather the diaper.
• the elastic members can be secured in an contractible condition in at least two ways. For example, the elastic members may be stretched and secured while the diaper is in an uncontracted condition. Alternatively, the diaper may be contracted, for example, by pleating, an elastic member secured and connected to the diaper while the elastic members are in their relaxed or unstretched condition.
• the elastic members may take a multitude of configurations.
• the width of the elastic members may be varied from about 0.25 mm to about 25 mm or more; the elastic members may comprise a single strand of elastic material or the elastic members may be rectangular or curvilinear.
• the elastic members may be affixed to the diaper in any of several ways which are known in the art.
• the elastic members may be ultrasonically bonded, heat and pressure sealed into the diaper using a variety of bonding patterns, or the elastic members may simply be glued to the diaper.
• the elastic members comprise a PHA of the present invention.
• the absorbent core of the diaper is positioned between the topsheet and backsheet.
• the absorbent core may be manufactured in a wide variety of sizes and shapes (e.g., rectangular, hour-glass, asymmetrical, etc.) and from a wide variety of materials.
• the total absorbent capacity of the absorbent core should, however, be compatible with the designed liquid loading for the intended use of the absorbent article or diaper. Further, the size and absorbent capacity of the absorbent core may vary to accommodate wearers ranging from infants through adults.
• a preferred embodiment of the diaper has an hour-glass shaped absorbent core.
• the absorbent core is preferably an absorbent member comprising a web or batt of airfelt, wood pulp fibers, and/or a particulate absorbent polymeric composition disposed therein.
• the absorbent polymeric composition of the absorbent core comprises a PHA of the present invention.
• absorbent articles according to the present invention are sanitary napkins designed to receive and contain vaginal discharges such as menses.
• Disposable sanitary napkins are designed to be held adjacent to the human body through the agency of a garment, such as an undergarment or a panty or by a specially designed belt.
• Examples of the kinds of sanitary napkins to which the present invention is readily adapted are shown in U.S. Patent 4,687,478, entitled “Shaped Sanitary Napkin With Flaps" which issued to Kees J. Van Tilburg on August 18, 1987, and in U.S. Patent 4,589,876, entitled “Sanitary Napkin” which issued to Kees J. Van Tilburg on May 20, 1986.
• films of the present invention comprising a PHA of the present invention described herein may be used as the liquid impervious backsheet of such sanitary napkins.
• the present invention is not limited to any specific sanitary napkin configuration or structure.
• sanitary napkins comprise a liquid impervious backsheet, a liquid pervious topsheet, and an absorbent core placed between the backsheet and the topsheet.
• the backsheet comprises a PHA of the present invention.
• the topsheet may comprise any of the topsheet materials discussed with respect to diapers.
• the adhesives used in may also comprise a PHA of the present invention.
• the absorbent core may comprise any of the absorbent core materials discussed with respect to diapers, including a PHA of the present invention.
• the absorbent articles according to the present invention are biodegradable and/or compostable to a greater extent than conventional absorbent articles which employ materials such as a polyolefin (e.g., a polyethylene) backsheet.
• a polyolefin e.g., a polyethylene
• Poly(3-hydroxybutyrate-co-3-hydroxy-4-methylvalerate) is prepared according to the general methods described above and based on the published procedure of Hori et al. (Hori, Y., M. Suzuki, Y. Takahashi, A. Yomaguchi, and T. Nishishita, MACROMOLECULES, Vol. 26, pp. 5533-5534 (1993)) for the polymerization of ⁇ -butyrolactone.
• the comonomer composition of the copolymer is determined by " ⁇ -NMR spectroscopy and found, within experimental error, to be the same as the charge ratio (95:5). Molecular weight is determined by size exclusion chromatography with chloroform as the mobile phase, and narrow polystyrene standards are used for calibration.
• Poly(3-hydroxyvalerate-co-3-hydroxy-4-methylvalerate) is prepared by following the same procedure as in Example 1 , with the exception that [S]-3- ethylpropiolactone (9.50 g, 94.9 mmol) and [S]-3-isopropylpropiolactone (0.71 g, 5.0 mmol) are used as the monomer charge.
• Poly(3-hydroxybutyrate-co-3-hydroxy-4-methylvalerate-co-3- hydroxyoctanoate) is prepared by following the same procedure as in Example 1 , with the exception that [S]-3-methylpropiolactone (9.50 g, 110 mmol), [S]-3- isopropylpropiolactone (0.41 g, 2.9 mmol), and [S]-3-pentylpropiolactone (0.50 g, 2.9 mmol) are used as the monomer charge.
• PHBMV polymethylvalerate/ 95 mole% butyrate
• PHBMV single screw extruder
• a constant taper screw having 20:1 length to diameter ratio and a 3:1 compression ratio is employed.
• the temperature of both heating zones of the extruder barrel is 25°C above the melt temperature of the PHBMV.
• the extruder is equipped with a die of width 6 inch and a die gap of 0.04 inch. The die is maintained at 20°C above the melt temperature of the PHBMV.
• the copolymer is melted within the extruder and pumped to the die at the other end of the extruder.
• the screw rpm is kept constant at 30 rpm.
• the copolymer is forced through the die and is collected on a take-up roll collection system (Postex) at a rate that allows crystallization of the polymer before take-up.
• Postex take-up roll collection system
• the width of these films are nominally 4 inch and the thickness are approximately 0.002 inch.
• Films of PHBMV are made by melting the material between Teflon sheets in a Carver Press (Fred S. Carver Inc., Menomonee Falls, WI) at 20°C above the melt temperature. Pressure on the sheets are adjusted to produce films of approximately 0.25 mm thick. The films are then identically cooled to room temperature by placing the molds between large (5 kg) aluminum plates and allowing the films to cool to room temperature.
• Sheets of PHBMV film may be prepared as in Example 6 of compositions PHBMV (95:5) and PHBMV (50:50). These sheets may then encase a sheet of a polymer with good oxygen barrier properties but a poor water vapor transmission rate, or a polymer film that may be water soluble such a poly(vinyl alcohol) (PVA).
• PVA poly(vinyl alcohol)
• the films are placed in carver press stacked in the following order PHBMV(95:5), PHBMV(50:50), PVA, PHBMV(50:50), PHBMV(95:5).
• the material is then pressed at a temperature 5°C above the melt temperature of PHBMV(50:50), but still below the melting temperature of the PHBMV(95:5). After compression at 2000 lb for 30 min, the pressure is released and the film is allowed to cool to room temperature.
• a disposable baby diaper according to this invention is prepared as follows. The dimensions listed are for a diaper intended for use with a child in the 6-10 kilogram size range. These dimensions can be modified proportionately for different size children, or for adult incontinence briefs, according to standard practice.
• Backsheet 0.020 - 0.038 mm film consisting of a 92:8 poly(3- hydroxybutyrate-co-3-hydroxy-4-methylvalerate) copolymer (prepared as described in Example 1 ); width at top and bottom 33 cm; notched inwardly on both sides to a width-at-center of 28.5 cm; length 50.2 cm.
• Topsheet carded and thermally bonded staple-length polypropylene fibers (Hercules type 151 polypropylene); width at top and bottom 33 cm; notched inwardly on both sides to a width-at-center of 28.5 cm; length 50.2 cm.
• Absorbent core comprises 28.6 g of cellulose wood pulp and 4.9 g of absorbent gelling material particles (commercial polyacrylate from Nippon Shokubai); 8.4 mm thick, calendered; width at top and bottom 28.6 cm; notched inwardly at both sides to a width-at-center of 10.2 cm; length 44.5 cm.
• Elastic leg bands four individual rubber strips (2 per side); width 4.77 mm; length 370 mm; thickness 0.178 mm (all the foregoing dimensions being in the relaxed state).
• the diaper is prepared in standard fashion by positioning the core material covered with the topsheet on the backsheet and gluing.
• a lightweight pantiliner suitable for use between menstrual periods comprises a pad (surface area 117 cm 2 ; SSK air felt 3.0 g) containing 1.0 g of absorbent gelling material particles (commercial polyacrylate; Nippon Shokubai); said pad being interposed between a porous formed-film topsheet according to U.S. Patent 4,463,045 and a backsheet which comprises a 0.03 mm thickness 92:8 poly(3-hydroxybutyrate-co-3-hydroxy-4-methylvalerate) copolymer copolymer film, as prepared in accordance with Example 1.
• EXAMPLE 11 Compostable Sanitary Napkin A catamenial product in the form of a sanitary napkin having two flaps extending outward from its absorbent core is prepared using a pad in the manner of Example 10 (surface area 117 cm 2 ; 8.5 g SSK air felt), per the design of U.S. Patent 4,687,478, Van Tillburg, August 18, 1987.
• the backsheet and topsheet materials are the same as described in Example 10.
• EXAMPLE 12 Compostable Sheet
• the film preparation procedure of Example 6 is modified by replacing the die on the extruder with a slot die of thickness approximately 0.25 cm and width 15 cm. Take-up after extrusion is accomplished by inserting the sheet emerging from the extruder between two counter-rotating cylinders. The sheet is drawn from the extruder in this manner and cut in lengths of 32 cm. Sheets of approximately 13 cm wide and 0.18 cm thick are obtained.
• Compostable Fiber PHBMV of composition 5 mole% methylvalerate/ 95 mole% butyrate is introduced into a single screw extruder (Rheomix Model 202) with screw diameter of 0.75 inch.
• a constant taper screw having 20:1 length to diameter ratio and a 3:1 compression ratio is employed.
• the temperature of both heating zones of the extruder barrel is 25°C above the melt temperature of the PHBMV.
• the extruder is equipped with a nozzle die containing 5 orifices of diameter 500 mm. The die is maintained at 20°C above the melt temperature of the PHBMV.
• the polymer is melted within the extruder and pumped to the die at the other end of the extruder.
• the screw rpm is kept constant at 30 rpm.
• the polymer is forced through the die and the melted extruded fibers are lead through a region where a rapid air stream is applied such that the polymer fibers elongates and thins to approximately one fifth of the diameter of the orifices (ca. 100 mm).
• the fibers are collected on a cardboard mat. A wide distribution of fiber lengths are obtained up several cm in length. Most fiber lengths (over 50%) are in the range of 1.3 to 15 cm.
• EXAMPLE 14 Compostable Rigid Foam PHBMV (40 g) of composition 5 mole% methylvalerate/ 95 mole% butyrate and 4 g of a common blowing agent, p,p'-oxy-bis benzenesulphonhydrazide are charged to the mixing chamber of a Rheomix type 600 melt blender equipped with roller blades. The mixing chamber temperature is heated above the melting temperature of PHBMV, but below the degradation temperature of the blowing agent (158°C). After mixing for 10 minutes at 60 rpm, the copolymer mixture is collected and is transferred to a heated aluminum pan, spread about so that the resulting mass is about 0.5 cm in thickness.
• the copolymer is then place in an oven (National Appliance Company, model 5830) and heated to the PHBMV melt temperature again, and is held at that temperature until the copolymer is completely molten (ca. 5 min).
• the oven temperature is then raised to 160°C at which temperature the blowing agent degrades and copolymer begins foaming.
• the copolymer foam is removed from the oven and is placed into a second oven at a temperature of the maximum crystallization rate of the PHBMV (about 80°C). The copolymer is left in this oven for 6 hours.
• Example 14 The procedure of Example 14 is used with the following modifications: 40 g of poly(3-hydroxybutyrate-co-3-hydroxy-4-methylvalerate) copolymer of composition 60 mole% methylvalerate/ 40 mole% butyrate (PHBMV (40:60)) is used in place of PHBMV (95:5).
• PHBMV poly(3-hydroxybutyrate-co-3-hydroxy-4-methylvalerate) copolymer of composition 60 mole% methylvalerate/ 40 mole% butyrate
• Injection molded articles are obtained by using a Mini Max Molder model CS-183 (Custom Scientific Instruments, Whippeny, N.J.). The temperature of the rotor and strator cup is held constant at 20°C above the melt temperature of the polyhydroxyalkanoate used. About 0.5 grams of PHBMV (95:5) is charged to the stator cup and allowed to melt for 3 minutes. The molten copolymer is radially mixed by raising and lowering the rotor tip five times. A dumbbell- shaped steel mold is sprayed with a light coating of mold silicone release agent. The mold is placed on the mold support wheel of the Mini Max Molder and the molten polymer is injected into the mold by action of the rotor tip.
• Mini Max Molder model CS-183 Customer Scientific Instruments, Whippeny, N.J.
• the copolymer is molded into a dumbbell shaped pieces 0.03 inch thick, 1 inch long, 0.125 inch wide at the middle of the piece and 0.25 inch wide at the ends. These molded parts are suitable for mechanical testing.
• EXAMPLE 17 Compostable Nonwoven Fabric
• PHBMV polyhydroxymethylvalerate/ 98 mole% butyrate
• a single screw extruder (Rheomix Model 202, Paramus, NJ) with screw diameter of 0.75 inch.
• a constant taper screw having 20:1 length to diameter ratio and a 3:1 compression ratio is employed.
• the temperature of both heating zones of the extruder barrel is 25°C above the melt temperature of the PHBMV.
• the extruder is equipped with a nozzle die containing 5 orifices of diameter 500 mm. The die is maintained at 20°C above the melt temperature of the PHBMV.
• the polymer is melted within the extruder and pumped to the die at the other end of the extruder.
• the screw rpm is kept constant at 30 rpm.
• the polymer is forced through the die and the melted extruded fibers are lead through a region where a rapid air stream is applied such that the polymer fibers elongates and thins to approximately one fifth of the diameter of the orifices (ca. 100 mm).
• the fibers are collected on a cardboard mat.
• the mat is moved in a fashion so that a 10 cm x 10 cm area is covered uniformly with fibers. Collection of fibers on the mat continues, until there is approximately 0.5 cm thick fiber mat. A wide distribution of fiber lengths are obtained up several inches in length. Most fiber lengths (over 50%) are in the range of 0.5 to 6 inches.
• the mat is then transferred to a Carver Press (Fred S. Carver Inc., Menomonee Falls, WI) and pressed at a 1000 lb force for 10 minutes at temperature 5°C below the melting temperature of the PHBMV. The resulting nonwoven sheet is removed from the press.
• Films of PHBMV are made by melting the material between Teflon sheets in a at 20°C above the melt temperature. Pressure on the sheets is adjusted to produce films of approximately 0.5 mm thick. The films are then identically cooled to room temperature by placing the molds between large (5 kg) aluminum plates and allowing the films to cool to room temperature. The films are aged for 2 days, then subsequently cut into strips 10 cm long and 1 cm wide. The strips are then placed in an Instron universal testing machine (Model 1122, Canton, MA) and are elongated at a rate of 1 in/min until 300% elongation of the original length is achieved. The films are held elongated for two days until crystallinity develops further. The strips are removed from the Instron and upon subsequent extension, the material returns to its former (post Instron treatment) length.
• Instron universal testing machine Model 1122, Canton, MA
• PHBMV (50:50) may be used as a hot-melt adhesive in the following manner. About 1g of PHBMV (50:50) is placed between two polymer films, such as poly(vinyl alcohol) (PVA), or poly(3-hydroxybutyrate) (PHB) or any other PHA which has a melting temperature at least 10°C higher than PHBMV (50:50). The films/adhesive assembly is placed in a Carver Press (Fred S. Carver Inc., Menomonee Falls, WI) and is then pressed at a temperature 5°C above the melt temperature of PHB:MV (50:50). After compression at 2000 lb force for 30 min, the pressure is released and the bonded film assembly is allowed to cool to room temperature.
• PVA poly(vinyl alcohol)
• PHB poly(3-hydroxybutyrate)

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